Reflector and liquid crystal display panel

Abstract

A reflector includes a heat-embossed layer having a reflective surface having a plurality of recesses, a highly reflective film laminated on the heat-embossed layer and having the reflective surface, and a moisture-proof base material laminated on the opposite side of the heat-embossed layer to the reflective surface. A liquid crystal display panel includes the reflector. The reflector may include an embossed layer having a reflective surface having a plurality of recesses, and an embossed base separable from the embossed layer and disposed on the opposite side of the embossed layer to the reflective surface.

1. A reflector attached to an outer surface of a glass substrate comprising:
 an adhesive layer attached to the glass substrate; 
 a reflective film; 
 a processed resin layer having a plurality of recesses, which define a reflection characteristic of the reflective film; and 
 a moisture-proof film base that supports the processed resin layer, 
 a support resin layer having a high glass transition temperature interposed between the processed resin layer and the moisture-proof film base, 
 wherein the support resin layer having a higher class transition temperature and lower moisture absorption property than those of the processed resin layer, 
 wherein the reflective film is disposed between the adhesive film and brought into direct contact with the processed resin layer such that a shape of the plurality of recesses of the processed resin layer is reflected in the reflective film and wherein the adhesive film and the glass substrate, in that order, are laminated upon the reflective film, wherein the recesses are formed in a spherical shape for reflection and randomly arranged, and contact portions between the recesses are formed in a peaked shape, and 
 wherein the moisture-proof film base includes a material with low moisture absorption and low moisture permeation and has a thickness of 0.05 to 1 mm. 
 
   
   
     2. The reflector according to  claim 1 , wherein the moisture-proof film base includes polyphenylene sulfide or polyvinylidene fluoride. 
   
   
     3. The reflector according to  claim 1 , wherein a thickness of the reflective film is between 80 nm and 200 nm. 
   
   
     4. The reflector according to  claim 1 , wherein the support resin layer includes polyphenylene sulfide or polyvinylidene fluoride. 
   
   
     5. The reflector according to  claim 1 , wherein the materials of the support resin layer and the moisture-proof film base are the same,
 wherein the support resin layer and the moisture-proof film base have the same material, and 
 wherein the support resin layer and the moisture-proof film base have flexibility. 
 
   
   
     6. A method of forming a reflector attached to the outer surface of a glass substrate, the reflector including an adhesive layer attached to the glass substrate, a reflective film, a processed resin layer having a plurality of recesses which define a reflection characteristic of the reflective film, a moisture-proof film base for supporting the processed resin layer, and a support resin layer having a higher glass transition temperature and lower moisture absorption property than those of the processed resin layer, the method comprising:
 pressing a roll-shaped embossing mother die having an irregular surface onto the surface of the processed resin layer, 
 rotating the roll-shaped embossing mother die to transfer the irregular shape of the roll to the processed resin layer, 
 interposing the support resin layer between the processed resin layer and the moisture-proof film base, 
 curing the processed resin layer, 
 reflecting the plurality of recesses of the process resin layer in the reflective film by bringing the reflective film into direct contact with the processed resin layer, and 
 laminating the adhesive film and the glass substrate, in that order, upon the reflective film 
 wherein the recesses are formed in a spherical shape for reflection and are randomly arranged, and 
 wherein contact portions between the recesses are formed in a peaked shape. 
 
   
   
     7. The method according to  claim 6 , wherein the roll-shaped embossing mother die includes a cylindrical embossing roll and an electroforming plate wound on the embossing roll, the surface of the electroforming plate having irregularities corresponding to the shape of the recesses. 
   
   
     8. The method according to  claim 6 , wherein the roll-shaped embossing mother die includes heating surface to heat the processed resin layer. 
   
   
     9. The method according to  claim 6 , wherein a thickness of the reflective film is between 80 nm and 200 nm.